FLEXIBLE COMPOSITE MULTIPLE LAYER FIRE-RESISTANT INSULATION STRUCTURE

• US 20090140097A1
• Filed: 10/29/2007
• Published: 06/04/2009
• Est. Priority Date: 03/26/2007
• Status: Active Grant

• Current Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Original Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Inventors: O'Riordan, Brian P., McGuire, Thomas P., Collier, Robert P.
• Granted Patent: US 8,062,985 B2
• Time in Patent Office: Days
• US Class Current: 244/121
• CPC Class Codes: B32B 15/04 comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 17/02 in the form of fibres or filaments
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: Y10T 428/232 Encased layer derived from inorganic settable ingredient
• CPC Class Codes: Y10T 428/237 Noninterengaged fibered material encased [e.g., mat, batt, etc.]
• CPC Class Codes: Y10T 428/239 Complete cover or casing
• CPC Class Codes: Y10T 442/2041 Two or more non-extruded coatings or impregnations
• CPC Class Codes: Y10T 442/3415 Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the woven fabric]
• CPC Class Codes: Y10T 442/3431 Plural fabric layers
• CPC Class Codes: Y10T 442/3439 Including a nonwoven fabric layer
• CPC Class Codes: Y10T 442/378 Coated, impregnated, or autogenously bonded
• CPC Class Codes: Y10T 442/3829 Four or more layers
• CPC Class Codes: Y10T 442/3854 Woven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/3976 Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]

Abstract

A flexible composite multiple layer fire-resistant insulation structure has a primary facing surface and a secondary facing surface. There is at least one dimensionally stable membrane having a primary membrane surface and a secondary membrane surface. At least a portion of the secondary facing surface is attached to the primary membrane surface. There is also at least one lofted insulative layer having a primary insulative surface and a secondary insulative surface. The at least one woven fabric facing layer may be formed of various materials, including amorphous silica glass and S-glass fiberglass. Different weaving patterns may be used to weave the facing layer. The facing layer may include a fire resistive treatment, which may in turn include a phosphate containing compound, and more particularly, may include dicalcium phosphate. In certain embodiments, multiple layers of the above are provided, and the structure may be enclosed in an abrasion resisting sheath.

Claims

1. A flexible composite multiple layer fire-resistant insulation structure, comprising:

at least one woven fabric facing layer having a primary facing surface and a secondary facing surface;

at least one dimensionally stable membrane having a primary membrane surface and a secondary membrane surface,

wherein at least a portion of the secondary facing surface is attached to the primary membrane surface; and

at least one lofted insulative layer having a primary insulative surface and a secondary insulative surface.

2. The structure of claim 1, wherein at least about 10% of the secondary facing surface is attached to the primary membrane surface.

3. The structure of claim 1, wherein at least about 30% of the secondary facing surface is attached to the primary membrane surface.

4. The structure of claim 1, wherein at least about 70% of the secondary facing surface is attached to the primary membrane surface.

5. The structure of claim 1, wherein the at least one woven fabric facing layer further comprises amorphous silica glass.

6. The structure of claim 1, wherein the at least one woven fabric facing layer further comprises S-glass including a fire resistive treatment.

7. The structure of claim 1, wherein the at least one woven fabric facing layer has a weave pattern further comprising at least a 2×

1 weave pattern.

8. The structure of claim 1, wherein the at least one woven fabric facing layer further includes a fire resistive treatment.

9. The structure of claim 8, wherein the fire resistive treatment further comprises a phosphate containing compound.

10. The structure of claim 9, wherein the phosphate containing compound further comprises dicalcium phosphate.

11. The structure of claim 1, further comprising;

an adhesive layer adhering at least a portion of the secondary membrane surface to the primary insulative surface.

12. The structure of claim 1, wherein the at least one membrane further comprises at least one metallic sheet layer.

13. The structure of claim 1, wherein the at least one membrane further comprises at least one polymeric layer.

14. The structure of claim 1, wherein the at least one lofted insulative layer is a fiberglass material.

15. The structure of claim 1, wherein the at least one lofted insulative layer is a foam material.

16. The structure of claim 1, wherein the structure is at least partially enclosed in a sheath.

17. The structure of claim 16, wherein the sheath is laminated by heat to the woven fabric facing layer,

18. A flexible composite multiple layer burn-through resistant insulation structure, comprising:

at least a first lofted insulative layer, positioned adjacent to;

at least a dimensionally stable membrane positioned adjacent to;

at least a first woven fabric facing layer, positioned adjacent to;

at least a second lofted insulative layer.

19. A flexible composite multiple layer fire-resistant insulation structure for increasing the burn through resistance of an aircraft fuselage having an exterior aspect and an interior aspect, comprising:

a composite having a woven fabric facing layer adjacent to the fuselage exterior aspect, and a lofted insulative layer adjacent to the fuselage interior aspect, wherein the woven fabric facing layer and the lofted insulative layer are separated by a dimensionally stable membrane.

20. The structure according to claim 19, wherein the facing layer and the membrane are adhered to each other.

21. The structure according to claim 19, wherein the facing layer and the membrane are adhered to each other, and the membrane and the lofted insulative layer are adhered to each other.

22. The structure according to claim 19, wherein the facing layer comprises a bidirectional woven fabric having S-glass fiberglass running in both directions of the weave, and the fabric further comprises a phosphate containing compound.

23. An aircraft fuselage having an outer surface, a plurality of structural members, and an inner surface, comprising;

a flexible composite multiple layer fire-resistant insulation structure disposed between the fuselage outer surface and the fuselage inner surface and substantially filling the space between at least two structural members;

wherein the structure further has a woven fabric facing layer disposed towards the fuselage outer surface; and

a lofted insulative layer disposed towards the fuselage inner surface; and

a dimensionally stable membrane adjacent to at least one layer chosen from the layers consisting of the facing layer and the lofted insulative layer.

24. A method of manufacturing a flexible composite multiple layer fire-resistant insulation structure, the steps comprising;

a) providing a woven fabric outer layer having an outer facing surface and an inner facing surface;

b) applying a high-phosphate heat-resistive treatment to at least one surface of the woven fabric outer layer;

b) disposing a dimensionally stable membrane having an outer membrane surface and a membrane inner surface such that the outer membrane surface is disposed on the inner facing surface;

c) disposing a lofted insulative layer having an outer insulative surface and an inner insulative surface such that the outer insulative surface layer is disposed on the inner film; and

d) enclosing the woven fabric, acoustic film, and lofted insulative layer in an abrasion resisting outer covering.